Motion characteristics analysis and magnetic adsorption module optimization of variable curvature adaptive wall-climbing robot for wind power tower

doi:10.3785/j.issn.1006-754X.2025.04.144

Chinese Journal of Engineering Design

2025, Vol. 32

Issue (2): 169-181 DOI: 10.3785/j.issn.1006-754X.2025.04.144

Robotic and Mechanism Design

Motion characteristics analysis and magnetic adsorption module optimization of variable curvature adaptive wall-climbing robot for wind power tower

Xiang LI¹(

),Ke LI²,Minglu ZHANG¹(

),Chunyan GAO¹,Manhong LI¹

^1.School of Mechanical Engineering, Hebei University of Technology, Tianjin 300401, China
^2.Taishan Nuclear Power Joint Venture Co. , Ltd. , Taishan 529228, China

Download:

HTML

PDF(6786KB)
Export: BibTeX | EndNote (RIS)

Abstract

Aiming at the problem that traditional wall-climbing robots cannot adapt to the variable curvature wall of wind power towers, taking the fast stability and turning flexibility of the wheeled mobile mechanism as the starting point, the attitude change of the wheeled mobile mechanism moving on the variable curvature wall was analyzed, and on this basis, a new wall-climbing robot adopting split wheeled movement and gap permanent magnetic adsorption technology was designed. Firstly, a multi-state motion model for the wall-climbing robot was established, and the adaptive motion characteristics of the robot moving on the variable curvature wall by using the attitude adjustment of its own split structure were analyzed. Then, the magnetic adsorption module of the wall-climbing robot was optimized, and the optimal structural parameters under high adsorption efficiency were obtained through parametric analysis. The experiment results showed that the structural design of the new wall-climbing robot was reasonable, and it could realize the adaptive and reliable motion on the variable curvature wall. The designed wall-climbing robot can provide an efficient and safe solution for the maintenance of wind power towers, which has important engineering application value.

Key words： wall-climbing robot variable curvature adaptive attitude adjustment split wheeled movement permanent magnetic adsorption

Received: 27 May 2024 Published: 06 May 2025

CLC:

TH 122

Corresponding Authors: Minglu ZHANG E-mail: 13315583895@163.com;zhangml@hebut.edu.cn

	Service
	E-mail this article
	Add to my bookshelf
	Add to citation manager
	E-mail Alert
	RSS
	Articles by authors
	Xiang LI
	Ke LI
	Minglu ZHANG
	Chunyan GAO
	Manhong LI

Cite this article:

Xiang LI,Ke LI,Minglu ZHANG,Chunyan GAO,Manhong LI. Motion characteristics analysis and magnetic adsorption module optimization of variable curvature adaptive wall-climbing robot for wind power tower. Chinese Journal of Engineering Design, 2025, 32(2): 169-181.

URL:

https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2025.04.144 OR https://www.zjujournals.com/gcsjxb/Y2025/V32/I2/169

风电塔筒用变曲率自适应爬壁机器人运动特性分析与磁吸附模块优化

针对传统爬壁机器人无法自适应风电塔筒变曲率壁面的问题，以轮式移动机构的快速稳定性和转弯灵活性为出发点，分析了轮式移动机构在变曲率壁面上运动时的姿态变化，并以此为基础设计了一种采用分体轮式移动和间隙式永磁吸附技术的新型爬壁机器人。首先，建立了多状态下的爬壁机器人运动模型，分析了机器人利用自身分体结构的姿态调整实现在变曲率壁面上移动时的自适应运动特性；然后，对爬壁机器人的磁吸附模块进行了优化，通过参数化分析得到了高吸附效率下的最优结构参数。实验结果表明，新型爬壁机器人结构设计合理，能够实现在变曲率壁面上的自适应可靠运动。所设计的爬壁机器人可为风电塔筒的维护作业提供高效、安全的解决方案，具有重要的工程应用价值。

关键词： 爬壁机器人, 变曲率自适应, 姿态调整, 分体轮式移动, 永磁吸附

Fig.1 Structure of split-type flexible variable curvature adaptive wall-climbing robot

Fig.2 Schematic diagram of flexible connection module

Fig.3 Schematic diagram of flexure hinge structure

Table 1 Key dimension parameters of flexure hinge

Fig.4 Schematic diagram of rapid replacement of front operation end

Fig.5 Sketch of curved attitude of conventional wall-climbing robot

Fig.6 Sketch of curved attitude of variable curvature adaptive wall-climbing robot

Fig.7 Relationship curves of

α

-

R

and

h 1

-

R

Fig.8 Sketch of curved attitude of optimized variable curvature adaptive wall-climbing robot

Fig.9 Relationship surface of

α

R

h 2

Fig.10 XOY surface projection of wall-climbing robot turning in place

Fig.11 XOZ surface projection of wall-climbing robot turning in place

Fig.12 Relationship surface of

α 1'

θ

R

Fig.13 Relationship surface of

α 1'

θ

h 2

Fig.14 Relationship surface of

α 1'

R

h 2

性能参数	数值
剩磁感应强度 $/ m T$	$1 ? 380 ~ 1 ? 420$
矫顽力 $/ k A / m$	923
最大磁能 $/ k J / m 3$	$366 ~ 390$
最高工作温度 $/ ℃$	$80$

Table 2 Performance parameters of NdFeB-N48

Fig.15 Schematic diagram of magnetic adsorption module structure

Fig.16 Magnetic induction intensity cloud map of magnetic adsorption module

Fig.17 Structural parameters of magnetic adsorption module

参数	初始值	参数	初始值
$φ 1 / °$	11	$h / m m$	28
$φ 2 / °$	11	$d / m m$	105
$φ 3 / °$	11	$t / m m$	5
$φ 4 / °$	11

Table 3 Initial values of structural parameters of magnetic adsorption module

Fig.18 Parameterized analysis results of magnetic adsorption module

参数	优化前	优化后
$φ 1 / °$	11	8
$φ 2 / °$	11	16
$φ 3 / °$	11	10
$φ 4 / °$	11	6
$h / m m$	28	26
d $/ m m$	105	105
t $/ m m$	5	6
$F m / N$	1 796.2	1 833.6
$η / N / k g$	350.7	403.9

Table 4 Optimization results of magnetic adsorption module

Fig.19 Variation curve of total adsorption force of magnetic adsorption module with clearance from wall

Fig.20 Variation curve of total adsorption force of magnetic adsorption module with wall thickness

Fig.21 Variable curvature adaptive wall-climbing robot system

参数	数值
机身尺寸^①/(mm $×$ mm $× m m$ )	680 $×$ 500 $×$ 410
质量/kg	55
最大负载/kg	110
载重自重比	2
可适应曲率半径/mm	$≥ 1 ? 500$
最大移动速度/(m/min)	8

Table 5 Parameters of wall-climbing robot

Fig.22 Wall-climbing robot load test site

Fig.23 Variable curvature adaptive motion experiment of wall-climbing robot

Fig.24 Stability and flexibility test experiment of wall-climbing robot

Fig.25 Change of swing angle at the hinge during longitudinal and oblique motion of wall-climbing robot

Fig.26 Turning experiment of wall-climbing robot

Fig.27 Change of swing angle at the hinge during turning of wall-climbing robot


[1]	马吉良，彭军，郭艳婕，等. 爬壁机器人研究现状及发展趋势［J］. 机械工程学报， 2023， 59（5）： 11-28. doi：10.3901/jme.2023.05.011 MA J L， PENG J， GUO Y J， et al. Research status and development trend of wall climbing robot［J］. Journal of Mechanical Engineering， 2023， 59（5）： 11-28. doi: 10.3901/jme.2023.05.011

[2]	钟道方，田颖，张明路. 轮腿式爬壁机器人的永磁吸附装置设计与优化［J］. 工程设计学报， 2022， 29（1）： 41-50. ZHONG D F， TIAN Y， ZHANG M L. Design and optimization of permanent magnet adsorption device for wheel-legged wall-climbing robot［J］. Chinese Journal of Engineering Design， 2022， 29（1）： 41-50.

[3]	NANSAI S， MOHAN R. A survey of wall climbing robots： recent advances and challenges［J］. Robotics， 2016， 5（3）： 14.

[4]	WANG B R， LUO H H， JIN Y L， et al. Path planning for detection robot climbing on rotor blade surfaces of wind turbine based on neural network［J］. Advances in Mechanical Engineering， 2013， 5： 760126.

[5]	姬昭鑫，陶友瑞，吴淼杰. 风电塔筒爬壁机器人吸附结构优化设计及试验研究［J］. 现代制造工程， 2023（1）： 35-42， 49. JI Z X， TAO Y R， WU M J. Optimization design and experimental research on adsorption structure of wind power tower wall climbing robot［J］. Modern Manufacturing Engineering， 2023（1）： 35-42， 49.

[6]	陈彦臻，胡以怀. 船体清洗机器人的开发现状与展望［J］. 船舶工程， 2017， 39（10）： 62-69. CHEN Y Z， HU Y H. Development status and prospect of ship hull cleaning robot［J］. Ship Engineering， 2017， 39（10）： 62-69.

[7]	杨怀林，刘春华，陈晓辉，等. 大型球罐壁面除漆机器人设计与实验研究［J］. 机械传动， 2024， 48（1）： 151-158. YANG H L， LIU C H， CHEN X H， et al. Design and experimental study of a large spherical tank wall paint removal robot［J］. Journal of Mechanical Transmission， 2024， 48（1）： 151-158.

[8]	冯传智，罗雨，许耀波，等. 管道全位置焊接机器人结构设计与运动学分析［J］. 机电工程， 2024， 41（8）： 1489-1499. FENG C Z， LUO Y， XU Y B， et al. Structural design and kinematics analysis of pipeline all-position welding robot［J］. Journal of Mechanical & Electrical Engineering， 2024， 41（8）： 1489-1499.

[9]	YANG P， SUN L Y， ZHANG M L. Design and analysis of a passive adaptive wall-climbing robot on variable curvature ship facades［J］. Applied Ocean Research， 2024， 143： 103879.

[10]	GO T， OSAWA T， NAKAMURA T. Proposed locomotion strategy for a traveling-wave-type omnidirectional wall-climbing robot for spherical surfaces［C］//2015 IEEE International Conference on Robotics and Biomimetics. Zhuhai， Dec. 6-9， 2015.

[11]	JIANG Z， MA Z， JU Z J， et al. Design and analysis of a wall-climbing robot for passive adaptive movement on variable-curvature metal facades［J］. Journal of Field Robotics， 2023， 40（1）： 94-109.

[12]	崔晓森. 风电塔筒运维用四足伸缩式爬壁机器人设计与分析研究［D］. 沈阳：沈阳工业大学， 2023. CUI X S. Design and analysis of a quadruped telescopic wall climbing robot for the operation and maintenance of wind power tower［D］. Shenyang： Shenyang University of Technology， 2023.

[13]	崔宗伟，孙振国，陈强，等. 两端吸附式焊缝修形爬壁机器人研制［J］. 机器人， 2016， 38（1）： 122-128. CUI Z W， SUN Z G， CHEN Q， et al. Wall climbing robot based on two-end adsorption for weld seam amending［J］. Robot， 2016， 38（1）： 122-128.

[14]	SEO T， SITTI M. Tank-like module-based climbing robot using passive compliant joints［J］. IEEE/ASME Transactions on Mechatronics， 2012， 18（1）： 397-408.

[15]	SEO T， SITTI M. Under-actuated tank-like climbing robot with various transitioning capabilities［C］//2011 IEEE International Conference on Robotics and Automation. Shanghai， May 9-13， 2011.

[16]	SONG Y F， YANG Z Y， CHANG Y， et al. Design and analysis of a wall-climbing robot with passive compliant mechanisms to adapt variable curvatures walls［J］. Robotica， 2024， 42（4）： 962-976.

[17]	ZHANG D， LI Z H， JIA P， et al. Optimization design and trajectory error compensation of a facade-adaptive wall-climbing robot［J］. Symmetry， 2023， 15（2）： 255.

[18]	韩强. 风电塔筒爬升装置及叶片与塔筒检测管理系统的开发［D］. 北京：华北电力大学， 2017. HAN Q. Development on the wind turbine tower climbing device and blades with towers detection management system［D］. Beijing： North China Electric Power University， 2017.

[19]	张栋，杨培，黄哲轩，等. 爬壁机器人悬摆式磁吸附机构的设计与优化［J］. 工程设计学报， 2023， 30（3）： 334-341. ZHANG D， YANG P， HUANG Z X， et al. Design and optimization of pendulous magnetic adsorption mechanism for wall-climbing robots［J］. Chinese Journal of Engineering Design， 2023， 30（3）： 334-341.

[20]	杨培，张明路，孙凌宇. 爬壁机器人磁吸附模块设计分析与结构参数优化［J］. 工程设计学报， 2024， 31（5）： 592-602. YANG P， ZHANG M L， SUN L Y. Design analysis and structural parameter optimization for magnetic adsorption module of wall-climbing robot［J］. Chinese Journal of Engineering Design， 2024， 31（5）： 592-602.

[1]	Chao QIN,Donglin TANG,Dongpan YOU,Chao DING,Sheng RAO,Yuanyuan HE. Research on navigation of wall-climbing robot based on improved RTAB-Map algorithm[J]. Chinese Journal of Engineering Design, 2025, 32(1): 32-41.

[2]	Pei YANG,Minglu ZHANG,Lingyu SUN. Design analysis and structural parameter optimization for magnetic adsorption module of wall-climbing robot[J]. Chinese Journal of Engineering Design, 2024, 31(5): 592-602.

[3]	Dong ZHANG,Pei YANG,Zhexuan HUANG,Lingyu SUN,Minglu ZHANG. Design and optimization of pendulous magnetic adsorption mechanism for wall-climbing robots[J]. Chinese Journal of Engineering Design, 2023, 30(3): 334-341.

[4]	ZHONG Dao-fang, TIAN Ying, ZHANG Ming-lu. Design and optimization of permanent magnet adsorption device for wheel-legged wall-climbing robot[J]. Chinese Journal of Engineering Design, 2022, 29(1): 41-50.

[5]	TANG Dong-lin, LI Mao-yang, DING Chao, WEI Zi-bing, HU Lin, YUAN Bo. Research on steering stability of wheeled wall-climbing robot[J]. Chinese Journal of Engineering Design, 2019, 26(2): 153-161.

Viewed

Full text

Abstract

Cited

Shared

Discussed